Classifications

• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05B—SEWING
  • D05B11/00—Machines for sewing quilts or mattresses
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05B—SEWING
  • D05B19/00—Programme-controlled sewing machines
  • D05B19/02—Sewing machines having electronic memory or microprocessor control unit
  • D05B19/12—Sewing machines having electronic memory or microprocessor control unit characterised by control of operation of machine
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05B—SEWING
  • D05B29/00—Pressers; Presser feet
  • D05B29/02—Presser-control devices

Definitions

• quilted fabrics which, foi example, a cover, a liner and one or more layers of filling material are joined to form an article such as a quilted furmtuie covei 01 a mattiess cover
• automated quiltmg machinery is commonly employed to stitch the layers of matenal togethei, with stitching applied in repeated patterns, or arrays of repeated patterns.
• High speed and economic pioduction of such quilted fabrics generally requires equipment utilizing arrays of needles, ganged together and driven through a common stitch forming mechanism, to apply a pluiahty of patterns simultaneously in a predetermined array.
• the layers of fabric are moved in unison with respect to the needles in order to place the next stitch at the desired point in the quilting pattern.
• a presser plate on one side of the multi-layered fabric is moved toward a needle plate on the other side of the fabric to compact the layers of material between the plates for the stitching process
• the presser plate is simultaneously lifted oi moved away from the needle plate, thereby permitting the material to be moved for the next stitch.
• the needles are mechanically coupled to and driven by a needle bar rocker shaft that, in turn, is mechanically connected to and driven by a continuously rotating drive shaft.
• the presser plate is also mechanically connected to and driven by the needle bar rocker shaft. The motion of the presser plate is thus mechanically and constantly fixed with respect to the motion of the needle.
• the presser plate With every stitch cycle, the presser plate usually starts a stitch cycle at the same uppermost position with respect to the needle plate, moves downwaid to the same lowermost position with respect to the needle plate and then retracts upward to the starting uppermost position. Thus, with each stitch, such a presser plate moves the same distance downward to the same material compaction position and then retracts the same distance to its uppermost starting position. Since the operation of the presser plate is mechanically fixed throughout the quiltmg process, the gap between the presser plate and the needle plate at any given point in the stitching cycle is always the same Therefore, a quilting machine is practically limited to stitching layers of material that have the same thickness.
• the relative motion of the presser plate is controlled by cams on a rocker shaft.
• a different quilting machine is generally used which has been configured to have a generally larger gap between the presser plate and the needle plate throughout the stitching cycle.
• the presser plate With a thicker quilt, the presser plate must have a higher starting position that allows the thicker quilt to be inserted thereunder and a higher, full compaction position that properly compresses the thicker quilt du ⁇ ng the stitching piocess.
• the lequiiement that different quiltmg machines must be used to stitch quilts having ditteient thicknesses presents significant disadvantages.
• the height of the piessei fool abo ⁇ e the needle plate is cntical to piopei stitch formation, sewing lehabihty and product quality
• the pressei foot height is determined p ⁇ manly by the thickness and density of the mate ⁇ als to be stitched
• users cu ⁇ ently adjust quiltmg machines to sew a specific thickness range, depending on expected production lequirements.
• the machine must be re-adjusted, usually by maintenance personnel in a procedure that involves significant amounts of time.
• An objective of the present invention is to provide a quilting machine and method that is flexible in its ability to produce quilts of different thicknesses
• a particulai objective of the invention is to provide for adjustment of presser foot position quilting processes so as to allow a single quiltmg machine to accommodate materials of differing thicknesses
• Further objectives of the invention include providing the correct presser foot setting for quilted products, particularly where the products are made automatically, and particularly where product thicknesses might change from one product to the next. Additional objectives of the invention are to provide quick presser foot adjustment lequning little opeiator skill oi experience, to leduce error m the making of presser foot adjustments.
• Particular ob j ectives of the invention are to provide for automatically making presser foot settings appropriate for each particular quilted product without the intervention of an operatoi. including by automatically providing a setting that has been predetermined to be appropriate for the product and by providing a setting that is sensed by the machine to be appropriate for the product.
• Other objectives of the invention are to provide a mechanism foi quickly changing presser foot settings that is durable, and to provide a mechanism by which the height of both the lower and upper presser foot positions and the distance between lowei and upper presser foot positions can be increased with the thickness of the material.
• the invention achieves various of its objectiv es by making adjustment of the presser foot height totally automatic for batch mode and automatic operation, with the optimum position of the pressure foot determined by the machine controllei computer based on product database information, motor torque feedback, material oi load sensors and other methods. For manual operation, adjustments can be made instantly with the simple touch of an icon.
• a quiltmg machine and method are provided with an adjustable drive linkage to quickly change the piessei foot setting The drive linkage is adjusted by a motoi oi other actuatoi, which is in turn lesponsive to a contiol signal produced m lesponse to a controller.
• the controllei in turn lesponds eithei to an input signal from an operatoi or facility computer or to information in a product database of a batch contiol system
• the presser foot linkage may operate to move end positions of the presser foot travel during each stitch cycle between two positions, among a plurality of more than two positions, or continuously between maximum and minimum settings Pieteiably, the actuatoi is out of the line of the mam dnve to the piessei foot 01 needle bar to minimize loads on the actuatoi and leduce failure rate of the dm e tram
• presser foot settings are changeable by operatoi input by lotatmg a knob 01 othei conti ol element 01 b ⁇ selecting an icon on the touch scieen of a controllei and inputting data to change the setting
• a product data file contains pattern information and othei paiameteis that define each of a pluia ty ol pioducts with such paiameteis including the piessme foot setting appiopnate foi the thickness of the particulai pi oduct
• sensors measuie oi otherwise respond to forces, torques power demands, compiessed material dimensions or other parameters that change as a function material thickness or density
• an apparatus foi stitching fabric to produce a quilted fabi ic The apparatus has a needle plate for supporting the fabric, a presser plate located above the needle plate and
• the piesser plate rocker shaft has input and output shafts that aie easily movable to different relative angular positions to locate the presser plate at a different positions with respect to the needle plate Fust and second positions of the piessei plate piovide, for example, respective fust and second gaps betw een the presser plate and the needle plate, which peimit fabrics of different thicknesses to be quilted
• the piessei plate locker shaft includes a coupling for moving the input and output shafts of the presser plate lockei shaft to the difteient angulai positions with respect to each othei
• the gap between the presser plate and the needle plate can be changed without changing the position of the needle
• One method of operating a quiltmg machine includes setting the presser plate to a fust position with respect to the needle plate loading a fust fabnc having a first thickness, stitching the fust fabnc setting the piessei plate to a second position with lespect to the needle plate without changing cams on the machine, loading a second fabnc having a second thickness, and stitching the second fabric
• a link is piovided to maintain a fixed component of the angulai position of the pressei plate lockei shaft
• a vanable actuatoi is provided m the lmk to change the fixed component
• the piessei lockei shaft oscillates about the fixed component angulai position so that changes in the actuatoi setting changes the uppei and lower positions of the piessei plate dunng its cycles
• the actuator may be any of a numbei of diffeient motors 01 devices, including, foi example, a two position pneumatic cylmdei, a senes of two position cvlindeis 01 a pneumatic 01 electncal actuatoi having moie than two positions, a stepping or seivo motor, or a continuous drive motor that may be, foi example, a lack and pinion drive or a worm gear, to name a few Where 0 the controller signals the actuator in response to an opeiatoi actuated input
• the present invention provides the advantages of a quiltmg machine and method substantially moie 5 flexible m operation than quiltmg machines and methods of the prior art
• the present invention permits the quiltmg machine to be easily leconfigured so that diffeient gaps can be easily set between a piesser plate and a needle plate, so that fabric layers of different thicknesses can be stitched on the same machine
• the invention permits one machme to serve a great many different maikets foi quilted fabrics
• small quantities of quilted fabrics of diffeient thicknesses can be economically supplied with a single machine
• Advantages of vanous embodiments of the invention include improved automation wheieby operators and maintenance personnel aie no longer lequned to do anything to adjust the pressei
• Fig. 1 is an elevation view of a quiltmg machine embodying the principles of the present invention
• Fig. 2 is a plan view of the front side of a fabnc quilted with an airay of disciete 360° patterns quilted on the quilting machine of Fig. 1
• Fig. 3 is a diagiammatic disassembled peispectiv e view of the pressei foot operating and related components of one embodiment of the quilting machine of Fig. 1. illustrating the relationships of actuatoi s and drives of the quiltmg station of the machine.
• Fig. 4 is a cioss-sectional end view of the quilting station embodiment of Fig. 3 illustrating the various interconnecting drives
• Fig. 5 is a perspective view of one set of the mechanical linkages used to operate the presser plate and needle bars of the embodiment of Fig. 3.
• Figs. 6A and 6B aie diagiammatic views lllustiatmg the uppermost and lowermost positions of the presser plate and needle with the pressei plate adjusted to stitch fabric having a lesser thickness in accordance with the embodiment of Fig. 3.
• Figs. 7A and 7B are diagrammatic views illustrating the uppermost and lowermost positions of the presser plate and needle with the piessei plate adjusted to stitch fabnc having a greater thickness in accordance with the embodiment of Fig. 3.
• Fig. 8 is a diagrammatic perspective view, similar to Fig. 3, illustrating presser foot adjusting system and related components of alternative embodiments of the invention and the relationship of actuators and drives.
• Fig. 8A is a cross-sectional view along line 8A-8A of Fig. 8 illustrating the presser plate drive linkage with the presser plate in its raised position and adjusted for minimum presser plate distance from the needle plate.
• Fig. 8B is a cross-sectional similar to Fig. 8A but with the presser plate adjusted for maximum presser plate distance from the needle plate
• Fig. 9 is a diagrammatic perspective view illustrating the variable linkage of the pressure foot adjusting system of Fig. 8.
• Fig. 9A is a diagrammatic perspective view of the variable linkage of Fig. 9. Detailed Description of the Invention
• the machine 20 includes a frame 22 assembled in one or more components on a plant flooi 24. Assembled to the frame 22 is a fabric material supply station 26 at the upstream end of the frame
• a quilt take-up station 28 at the downstream end of the frame 22 22, a quilt take-up station 28 at the downstream end of the frame 22, and a quiltmg station 30 between the supply station 26 and the take-up station 28
• a stitch pattern is applied to a multiple layered fabric 32 to form a quilt 34. which then passes to the take-up station 28 where it is wound upon a take-up roll 36, which is rotatably supported on a transverse axle to the fiame 22 at the take-up station 28.
• the fabnc 32 is formed of one or more layers of fillei material 38 from supply rolls 40 mounted on horizontal transv erse axles to the frame 22 at the supply station 26
• the filler material 38 is fed downs ⁇ 'eam from the supply station 26 around guide rollers 42 and between two layers of cover material, including an outei cover 44 from a supply roll 46 lying in a trough mounted to the frame 22 above the flights of filler material 38 at the entry end 48 of the quilting station 20, and a lmer or backing 50 from a supply roll 52, rotatably mounted on a transverse axle to the frame 22 below the filler material 38 at the entry end 48 of the quilting station 30
• the layeis of matenal 38 44 and 50 aie biought togethei at a rollei station 54 at the entiy end 48 of the quiltmg station 30 to foi the fabnc 32
• the lollei station 54 includes tw o pan of tiansv eisely extending trans eise
• the fabnc 32 is se n, ith a stitch forming mechanism into an ays 62 of a quilted pattern 64 (Fig. 2) fiom a pluiahty of needle thieads 68 horn a pluiahty of needle thread spools 70 mounted on the frame 22 near the supply station 26, and a pluiahty of looper threads 72, from a plurality of looper thread spools 74 mounted on the frame 22 beneath the quiltmg station 30
• the needle thieads 70 pass thiough a bank of thread tension adjusteis at the front side of the name 22 at the quiltmg station, p ⁇ oi to passing to the quiltmg station 30
• These adjusters are mechanically settable to piovide piopei thiead tension They aie also contiolled by pneumatic solenoid contiolled actuators to switch between a tension state, at which the set tension is applied to the needle threads 70, and a release state, at which no tension or minimum tension is applied to the thieads 70
• separate thread clamps may be provided at a position along the thiead close to the needles, however, then exact location is dependent on the elasticity of the thiead and is selected to avoid thiead snap-back and unthieadmg of the needles
• Other details of the quiltmg machine 20 lllustiated in Fig. 1 aie set forth in U S Patent No 5, 154
• a needle plate 78 supports the fabric 32 as patterns, such as pattern 64
• Needle plate 78 has a matrix of needle recei ing holes 80 spaced appioximately one inch apart in paiallel rows that aie spaced about six inches apart
• a presser foot or plate 82 located above the needle plate 78, moves down to piess the fabnc 32 against the needle plate 78 to hold the fabnc as needles 84 extend through it. and the pressei plate 82 mov es up to allow the fabnc 32 to be moved
• the pressei plate 82 also has a matiix of holes 86 which co ⁇ espond to the matnx of needle holes 80 in the needle plate 78
• each of the holders 90 includes a vertical groove and a clamping screw positioned in a fhieaded hole beside the groove to clamp the needle securely in position
• the needles 84 are mounted in an an ay on the needle bais 88 to define the relative spacings of patterns such as pattern 64 in pattern a ⁇ ay 62 (Fig.
• the array 62 of disci ete patterns such as the pattern 64 of Fig. 2 is achieved by programmed motion of the fabric 32 transverseh and longitudmallv bv motion of the feed lolleis 56 and 58 moving synchiomsm with the operation of the piessei plate 82 and needle bai s 88 to foim stitches preferably of equal length in the pattern shape.
• the 360° patterns 64 of the an ay 62 aie accomplished by forwaid and leverse lotation of the feed lolleis 56 and 58 as well as transveise lecipiocatmg motion of the rolleis 56 and 58
• the fabric 32 feeds generally in the direction of the arrow 99.
• the lollers 56 and 58 are also shiftable tiansveisely. in synchronism with each other, by transverse rollei drive 98
• transverse rollei drive 98 These roller drives 96 and 98 aie electronically linked to the operation of the presser plate 82 and needle bars 88 by a controller 109
• the rotary feed drive 96 is driven by feed motor 102 while the transverse drive 98 is driven by shift motoi 104.
• the latio and relative dnection of the drives 96 and 98 and operation of the presser plate 82 and needle bars 88 is controlled m response to a computer, containing a pattern program, within the controller
• the controller 100 permits the drives 96 and 98 and the motors 102 and 104 can be driven in synchronism with, or disengaged from, the presser plate 82 and needle bars 88, which are driven by a separate drive motor 106.
• Each of the motors 102, 104. 106 can be locked in position while the others are activated, under control of the controller 100.
• the controller 100 furthei contiols needle and looper thread tensioners 101 and responds to the states of door interlocks 103 in a know n mannei 0
• An output shaft of the motoi 106 is connected to a main drive shaft 108 that extends transversely to the fabric feed direction along the length of the quilting station 30
• the main drive shaft 108 lotates continuously but by means of an eccentric coupling, imparts a linear oscillating motion to a mechanical linkage 110 that drives a needle bar and presser plate leciprocatmg assembly 1 15
• the mechanical linkage 1 10 reciprocates as illustrated by arrow 107 to impart angulai oscillations to the needle bar locker shaft 1 12 as indicated by the a ⁇ ow 1 14 and 5 operate the needle bar and presser plate reciprocating assembly 1 15.
• the angular displacement or amplitude of the angular oscillation is determined by the eccentric drive coupled to the mam drive shaft 108 and the mechanical linkage 110 interconnectmg the needle rocker shaft 1 12 with the main drive shaft 108.
• the needle rocker shaft 112 extends transversely to the fabric feed direction along the length of the quilting station 30.
• mechanical linkage 1 16 mteiconnects the needle bars 88 with the needle locker shaft 1 12 and functions to convert the l ecipi ocatmg angulai oscillations of the needle bai rocker shaft 1 12 into a vertical reciprocatmg motion of the needle bars 88 as indicated by the arrow 1 17.
• the linear displacement or amplitude of the reciprocatmg motion of the needle bars 88 is a function of the magnitude of the oscillation of the needle bai rocker shaft 112 and the mechanical linkage 1 16.
• Mechanical linkage 1 18 connects a piessei plate locker shaft 1 19 with the needle bai lockei shaft 1 12 5
• the piesser plate rockei shaft 1 19 is comprised of an assembly of a presser plate input rocker shaft 120, a pressei plate output rockei shaft 122 and a static phase adjusting coupling 124 connected between the shafts 120, 122.
• the static phase adjusting coupling 124 p ⁇ ides angulai adjustment between the input and output presser plate lockei shafts 120 and 122 and provides the presser plate adjustment which determines the spacing between the presser plate 82 and the needle plate 7 8 at the low ei most and uppei most positions of the piessei plate 82 m each stitch cycle
• the coupling 124 set any position, in the couise of the stitching cycles, the piesser plate rockei shaft 1 19 oscillates through an angular displacement repiesented by the arrow 123.
• the magnitude or angulai displacement with each oscillation of the pressei plate lockei shaft 1 19 is a function of the amphmde of the oscillation of the needle bar locker shaft 1 12 and the mechanical linkage 1 18 interconnecting the shafts 1 12,120.
• Mechanical linkage 126 mtei connects the output pressei plate lockei shaft 122 with the presser plate 82 and imparts a reciprocating vertical motion to the pressei plate 82. as indicated by a ⁇ ovv 125. in response to the angulai oscillations of the output presser plate rocker shaft 122.
• the linear displacement or amplitude of each reciprocation of the presser plate 82 is a function of the angulai displacement of the oscillation of the output presser plate locker shaft 122 and the mechanical linkage 126
• the opeiation of the drive motor 106 causes the presser plate 82 to move through a vertically hneai reciprocating motion that is synchronized with a vertically linear reciprocating motion of the needle bars 88, thereby permitting the fabric 32 to be moved by the feed rollers 56. 68 and the drive 96 to desired different locations between each stitching cycle.
• a manually operable version of the static phase adjusting coupling 124 is a 360° positioner commercially available from Candy Controls of Niles, Illinois.
• the phase adjusting coupling 124 is used to change the relative angular position of the output presser plate rocker shaft 122 with respect to the mput presser plate rocker shaft 120, thereby changmg the amplitude of the reciprocating linear motion of the presser plate 82 as well as the location of that reciprocating motion with respect to the needle plate 78
• the gap between the presser plate 82 and needle plate 78 is thereby adjustable to permit quilts of different thicknesses to be stitched by the quilting station 30.
• This adjustment of the coupling 124 may be made by a servo motoi 129 opei ating m l esponse lo a signal fiom the conti ollei 100. or may be made manually, by turning an adjustment ring, foi example.
• Figs. 3-5 illustrate furthei details of the drive mechanisms for the presser plate 82 and needle bais 88.
• drive shaft 108 and lockei shafts 1 12. 1 19 extend ttansversely to the direction of feed of the fabric 32 across the full length of the quilting station 30 and are supported by bearings at both ends of the shafts
• the linkage 110 connecting the drive shaft 108 to the needle bar rocker shaft 1 12 is normally located at one end of the shaft 108.
• One or moie mechanical linkage 1 10 can be used to mechanically couple the shaft 108 to the needle bar rockei shaft 112.
• identical mechanical linkage 1 10 can be located at opposite ends of the drive shaft 108.
• the mechanical linkage 1 18 interconnecting the needle bar rocker shaft 1 12 with the presser plate rocker shaft 119 may be located at any point on the drive shaft 108 but normally is located close to one end of the drive shaft 108 and mside of the mechanical linkage 1 10.
• a number of mechanical linkages 1 16 interconnecting the needle bai locker shaft 112 to the needle bars 88 are equally spaced over the length of the quiltmg station 30
• a mechanical linkage 126 interconnecting the presser plate rockei shaft 1 19 with the pressei plate 82 is located ovei the length of the piessei plate locker shaft 1 19 adjacent to each of the mechanical linkdues 1 16 Retell ing lo F igs. 3 and 4.
• the main di n e shall 108 includes an eccentnc cam 128
• the mechanical linkage 1 10 is comprised of a connecting lod 130 jouinalled at one end aiound the mam drive shaft 10S and eccentric 128.
• the connecting lod 130 is pivotally connected at its opposite end to the distal end of a needle bai rocker lever 132.
• the pioximal end of " the level 132 is clamped oi othei wise mechanically fixed onto the needle bai lockei shaft 1 12
• lotation of the din e shaft 108 by motoi 106 (Fig. 3) causes the connecting rod to reciprocate in a direction parallel to its longitudinal center line.
• the hneai displacement oi amplitude of each reciprocation is a function of the eccentricity of the eccentnc cam 128.
• the mechanical linkage 1 18 connecting the needle bar rocker shaft 1 12 with the input presser plate rockei shaft 120 is comprised of a first driving lever 133 and a connecting link 135 and a driven lever 137.
• the proximal end of the driving lever 133 is clamped or otherwise mechanically fixed to the needle bar rocker shaft 1 12.
• the distal end of the driving lever 133 is pivotally connected to one end of the connecting link 135 and the opposite end of the connecting link 135 is pivotally connected to the distal end of the driven lever 137.
• the proximal end of the driven levei 137 is clamped oi otherwise mechanically fixed to the input presser plate rocker shaft 120.
• the mechanical linkage 1 16 connecting the needle bar rocker shaft 112 to the needle bars 88 is comprised of a needle bar drive lever 134 and a needle bar connecting rod 136.
• the proximal end of the needle bar drive lever 134 is clamped or otherwise mechanically fixed to the needle bar rocker shaft 1 12. and the distal end of the needle bar drive lever 134 is pivotally connected to an upper end of the needle bar connecting rod 136.
• the lower end of the needle bar connecting rod is pivotally connected with respect to a cross member 92 that is clamped or otherwise rigidly connected to the needle bars 88
• the cross member 92 has a guide rod 158 extending vertically upward through a name member 140 to ensure that the needle bars 88 reciprocate m a vertical direction.
• the mechanical linkage 126 connecting the output presser plate rocker shaft 122 to the presser plate 82 includes a presser plate lever 138. a pressei" plate dnve link 141 and a piesser plate guide rod 142 The pioximal end of the presser plate lever 138 is clamped or otherwise mechanically secured to the output presser plate rocker shaft 122. The distal end of the presser plate level 138 is pivotally connected to an upper end of the presser plate drive link 141.
• the presser plate guide rod 142 is mounted withm bearings (not shown) that m turn are supported by a frame member 150.
• the lowei end of the presser plate drive link 141 is pivotally connected to a presser plate block 142 that is clamped or otherwise mechanically secured to an upper end of a presser plate guide lod 144.
• the lower end of the presser plate guide lod terminates into a presser plate mounting block 146 that is secured to the presser plate 82 by fasteneis 148 or othei means
• oscillations of the needle bar rocker shaft 112 are transmitted via the mechanical linkage 1 18 to the pressei plate rockei shaft 1 19 Angular oscillations of the pressei plate locker shaft 119 aie tiansfe ⁇ ed via mechanical linkage 126 to vertical reciprocations of the presser plate 82
• the quiltmg machine 20 is illustrated as set up to establish a gap between the presser plate 82 and the needle plate 78 that is suitable to stitch layers of fabric 32 that are relatively mm.
• the presser plate 82 is located approximately 0.25 inches above the needle plate 78, and a first fabric 32 having a first thickness is loaded into the quilt g station 30 and located betw een the piesser plate 82 and the needle plate 78
• mechanical linkage 116 shown m Figs. 3-5 causes the needle 84 to begin tiavehng vertically downwaid as pieviously described. Furthei.
• the pressei plate 82 and needle 84 continue their downward motion until the needle bar lockei shaft 1 12 lotates thiough an angular displacement of appioximately 40° to the position illustrated in Fig. 6B
• the mechanical linkage 118 causes the piesser plate rocker shaft 1 19 to rotate thiough an angulai displacement of appioximately 25° to the position illustrated in Fig. 6B.
• the piessei plate 82 and needle 84 will be at then loweimost positions pioviding the smallest gap between the pressei plate 82 and the needle plate 78.
• the presser plate 82 has moved downward through a stroke of 0 125 inches. thereby causing the presser plate 82 to compact the material 32 to a thickness of approximately 0.125 inches.
• the needle bar locker shaft 112 then reverses direction and rotates back through the 40° angular displacement to the position illustrated m Fig. 6A, thereby retracting the needle 84 from the material 32 and rotating the presser plate rocker shaft 1 19 and lifting the presser plate 82 to then lespective original positions.
• the feed rollers 56, 58 and transverse drive 96 then move the material 32 to an appropriate location for the next stitch as required, for example, by the pattern 64.
• the quiltmg machine is stopped; and the static phase adjusting coupling 124 is utilized to change the height of the piessei plate 82. theieby changing the gap between the presser plate 82 and the needle plate 78.
• the coupling 124 has an outer ring 131 which is unlocked by activation of a solenoid 139 in response to a signal from controller 100 Then, the ring 131 rotated in a direction causing the presser plate rocker shaft 1 19 to turn counteiclockwise as viewed in Fig. 7A Thus, by rotating the outer ring of the static phase couplmg 124.
• the input piesser plate locker shaft 120 lemains stationary, but the output presser plate rocker shaft 122 will rotate, for example, counterclockwise, as viewed in Fig. 7A.
• Each revolution of the outer ring of the phase coupling 124 results in a rotation of approximately 3 6° of the outer presser plate rocker shaft 122. If it is desired to provide a gap between the presser plate 82 and needle plate 78 of approximately 0.6275 inches as illustrated m Fig. 7A.
• the output piesser plate locker shaft 122 will have to be moved approximately 24° m the counterclockwise duection
• the outei nng of the phase adjusting coupling 124 must be mov ed through appioximately 6 7 revolutions
• the presser plate 82 having the desned gap or distance fiom the needle plate 78.
• the outei ring of the phase coupling 124 is then locked into position, and the stitching cycle may be initiated In this example, using the coupling 124.
• the gap between the presser plate 82 and the needle plate 78 is easily mcieased to approximately 0.6275 inches as illustrated in Fig. 7A.
• a second fabric 32 having layeis of a second thickness aie loaded mto the quiltmg machine 20. 5 and the operation of the quiltmg machine is started
• a stitching cycle is executed corresponding to that shown m Figs. 7A, 7B which, except for the size of the gap between the piesser plate 82 and the needle plate 78, is substantially the same as the cycle lllustiated in Figs. 6A, 6B. That is. from the highest, fully retracted position of the piesser plate 82 and needle 84 lllustiated in Fig. 7A to the fully extended, lowermost position of the piesser plate 82 and needle 84 lllustiated in Fig. 7B. the needle bar rocker shaft 1 12 rotates through approximately
• the mechanical linkage 118 with the piesser plate rocker shaft 1 19 causes the presser plate rocker shaft 1 19 to rotate clockwise through an angulai displacement of appioximately 25° That angular displacement of the presser plate rocker shaft 119 causes the presser plate 82 to move downward through a compression stroke of approximately 0.375 mches to provide full compression with a gap of appioximately 0.25 inches between the presser plate 82 and needle plate 78.
• the needle bai locker shaft 1 12 then leveises direction and rotates counterclockwise through an
• the present invention provides a quiltmg machine and method that is substantially more flexible in its operation
• the quiltmg machine of the present invention permits different gaps between the presser plate 82 and the needle plate 78 to be easily set, so that fabric layers of different thicknesses can be stitched on the same machine. 0
• the gap between the presser plate 82 and the needle plate 78 is adjusted simply in seconds by changing the setting of the static phase coupling 124, and it is not necessary to exchange cams or other mechanical components which requires many hours of complex and difficult labor to accomplish.
• the quiltmg machine of the present invention pi ovides its user with oppoi amities to supply diffeient quilted products in a way that was not possible in the past with a single quilting machine.
• a lever arm 132 is utilized to impart angulai oscillations to the needle bar rocker shaft 1 12.
• a second lever arm 133 is used to transmit an angular oscillation from the needle bar rocker shaft 112 to the presser plate locker shaft 1 19
• the levers 132 and 133 may be integrated into a single unitary lever that extends fiom either one side or both sides of the needle bar rocker 0 shaft 1 12
• the disclosed embodiment in Fig.3 illustrates the motor 106 directly driving the drive shaft 108
• the motor 106 and drive shaft 108 may be mechanically coupled with other devices, foi example, timing belts, chains, etc., in a know n mannei
• the quilting station 30 illustrated in Figs. 3-5 provides two needle bars 88. Different numbers of needle bars 88 may be utilized by the quiltmg station.
• the static phase coupling 124 is independent of the lelative degiee of automation of the quiltmg machine Othei embodiments aie lepiesented by Figs. 8 thiough 9B, in which an alternative needle bar and piessei plate lecipiocatmg assembly 215 is piovided having a vanable linkage 218 which replaces the linkage 1 18 and provides the pressuie plate adjustment function provided by the assembly of the split shaft 119 and the static phase adjusting coupling 124 thei eof
• the variable linkage 218 connects the needle bar rocker shaft 1 12 with a solid one 5 piece presser plate rocker shaft 219, and includes a first driving lever block assembly 233, a connecting link 235 and a driven lever block assembly 237
• the proximal end of the driving lever block assembly 233 is clamped oi otherwise rigidly attached fixed to the needle bar rocker shaft 1 12.
• the distal end of the driving lever block assembly 233 is
• the mechanical linkage 126 connects the presser plate rocker shaft 219 to the presser plate 82 and includes the presser plate lever 138, the piesser plate dnve link 141 and the presser plate guide rod 142.
• the proximal end of the piessei plate level 138 is clamped oi otherwise mechanically secured to the presser plate rocker shaft 219
• the distal end of the presser plate lever 138 is pivotally connected to an uppei end of the piesser plate drive link
• the presser plate guide rod 142 is mounted within bearings (not shown) that in turn are supported by a frame member 150.
• the lower end of the presser plate drive link 141 is pivotally connected to a presser plate block 142 that is clamped or otherwise mechanically secured to an upper end of a presser plate guide rod 144.
• the lower end of the presser plate guide rod terminates into a presser plate mounting feet 146 that is secured to the presser plate 82 by fasteners or other means
• variable linkage 218 tiansmits the oscillating motion of the needle rocker shaft 1 12 to the presser plate rocker shaft 219 to drive the piesser plate 82 between it's lo ermost point of travel closest to the needle plate 78. wheie it compiesses the matenal to its maximum state of compiession for sewing a stitch, and its uppermost point
• variable linkage 218 is adjusted by effectively varying the length of the linkage 218 to change the lowermost and uppermost points of travel of the presser plate 82.
• the length of the linkage is varied by moving the axis of pivot between the connecting link 235 and the driven lever block assembly 237 to effectively change the length of " the connecting link 235 and the angular adjustment of shaft
• the axis is the centerlme of an eccentric lobe 226, which, when rotated, increases or decreases the distance between the actual pivot points of the link 235 in the block assembly 237. This results in a corresponding change in the presser foot height
• the eccentnc lobe 226 is mounted with bearings 231, 232 in both the lever block assembly 237 and the link 235.
• a mechanism that includes a geai 227 on one end of the shaft of the eccentric lobe 226 and a geaied lev ei 228 mechanism pivotally mounted on the block assembly 237 rotates the
• eccentric lobe 226 35 eccentric lobe 226.
• the geared lev ei 228 lotates on beaiing 239 about the pressei foot rocker shaft 219 and is held in place with a collai 234.
• a hneai motoi or actuator 229 described here as a two position bidirectional pneumatic cylindei. is mounted on the block assembly 237 and actuates the mechanism of gear 227 and lever 228. forcing a stop levei 230 against a mechanical stop 235 at either end of the rotary travel of " the eccentric lobe 226.
• the geai 227 and stop lever 230 are keyed to the eccentnc shaft 226 w ith a key 236.
• a pneumatic contiol v alve (not shown) actuates the cylmdei.
• the machine contiollei 100 opeiates the pneumatic contiol alv e and thereby toggles the pressure foot setting between a highei and lower setting
• the mechanical parts can be divided into two categories.
• One category includes the force transmitting parts, which aie levei block 233. link 235. eccentnc lobe 226. bearings 231 and 232 and lever block 237. which transmit the heavy forces lequned to be tiansmitted from the rockei shaft 1 12 to the presser foot rocker shaft 219.
• the other categoiy includes position holding parts and parts that provide adjustability, which are pneumatic cylinder 229.
• the actuatoi oi motoi 229 can be in the form of a double acting two position pneumatic cylinder, solenoid or other double acting motor, or it may be in the form of a multiple position motor that can adjust the linkage among a plurality of discrete positions or infinitely over a range.
• greater adjustability than is provided by a smgle double actmg actuatoi can be achieved by adding a second eccentric system into the linkage 218 in series with the first eccentric lobe element 226, for example by adding a similar lobe m place of pivot shaft 444 on the other end of the link 235.
• An additional double acting actuator 229 would be provided to switch this lobe between two positions, thereby producing a total of four adjustments or presser foot positions rather than two, depending on which actuator 229 were actuated: one, the other, neither, or both.
• Infinite adjustability could be provided by using, instead of a two position cylinder for the actuator 229, using a multiple position actuator to rotate the eccentric to more than only two positions This can be achieved by incorporating a motor such as a stepping motor or other device capable of stopping and holding the eccentric in either a plurality of discrete positions or an infinite number of positions within its range of travel.
• the actuator may be controlled to adjust the presser foot height in several ways.
• several modes of control aie provided, including a manual mode, hich gives an operator the flexibility to set or change the pressei foot height, a batch mode, in w hich the contioller signals the actuatoi to make set the height that has been predetermined to be appropriate for the product being quilted, and an automatic mode in which sensors measure one or more parameters during the quilt g operation to determine the height setting appropriate for the material bemg quilted.
• the controller 100 sends a signal to the actuator 229 to execute the adjustment. Similar control modes can be used for the actuatoi 129 in the embodiment of Figs. 3-7B discussed above
• a touchscieen icon foi selecting manual operation of the presser foot setting is incorporated into the opeiator interface of the controller 100
• screen contiols aie presented to the operator by which a pressei foot setting oi setting change can be entered to the controller 100.
• the manual setting is preferably made when the machine is stopped for adjustment so that the high forces present during high speed quilting are not encounteied during adjustment.
• Automated setting can be synchronized to those points m the quiltmg machine cycle when the adjustments can be made.
• information regarding proper presser foot height is included in a product database that includes data for all of the automatic parameter settings to produce each product scheduled on the quilting machine.
• Adjustments aie made automatically by the controllei 100 at the correct time in the quiltmg process as the materials are in tiansition undei the piesser foot More detailed explanations of batch mode contiol aie set forth m Foi ' batch mode" U S Patent No 3 ⁇ >44 ⁇ 99 and U S Patent Application Senal No 09/301 6:>3 filed April 28 1999 bv Fiazei et al entitled Quilt Making Automatic Scheduling Sv stem and Method, both heiebv expiessly mco orated by refeience herein

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Computer Hardware Design (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Sewing Machines And Sewing (AREA)

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• 2000
  • 2000-03-02 US US09/517,239 patent/US6170414B1/en not_active Expired - Lifetime
  • 2000-05-04 JP JP2000617247A patent/JP2002543899A/ja active Pending
  • 2000-05-04 CN CN00807284.1A patent/CN1119448C/zh not_active Expired - Fee Related
  • 2000-05-04 AU AU49838/00A patent/AU4983800A/en not_active Abandoned
  • 2000-05-04 CA CA002372870A patent/CA2372870A1/en not_active Abandoned
  • 2000-05-04 WO PCT/US2000/012109 patent/WO2000068481A1/en not_active Application Discontinuation
  • 2000-05-04 EP EP00932053A patent/EP1183413A4/de not_active Withdrawn

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